2009 YAMAHA TTR110 wheel

TABLE OF CONTENTS
SAFETY INFORMATION .................. 1-1
DESCRIPTION .................................. 2-1
Left view .......................................... 2-1
Right view ........................................ 2-2
Controls and instruments ................2-3
INSTRUMENT AND CONTROL
FUNCTIONS....................................... 3-1
Main switch ..................................... 3-1
Handlebar switches ........................ 3-1
Shift pedal ......................................3-2
Brake lever ..................................... 3-2
Brake pedal .................................... 3-3
Fuel tank cap .................................. 3-3
Fuel ................................................ 3-3
Fuel tank breather hose ................. 3-5
Fuel cock ........................................ 3-5
Starter (choke) lever ....................... 3-6
Kickstarter ......................................3-7
Seat ................................................ 3-7
Shock absorber assembly .............. 3-8
Sidestand ....................................... 3-8
Starting circuit cut-off system ......... 3-8
FOR YOUR SAFETY –
PRE-OPERATION CHECKS.............. 4-1
Pre-operation check list .................. 4-2OPERATION AND IMPORTANT
RIDING POINTS................................ 5-1
Starting and warming up a cold
engine ......................................... 5-1
Starting a warm engine .................. 5-2
Shifting ........................................... 5-2
Engine break-in .............................. 5-3
Parking ........................................... 5-4
PERIODIC MAINTENANCE AND
ADJUSTMENT................................... 6-1
Owner’s tool kit .............................. 6-2
Periodic maintenance chart for
the emission control system ....... 6-3
General maintenance and
lubrication chart .......................... 6-4
Removing and installing panels ..... 6-6
Checking the spark plug ................ 6-7
Engine oil ....................................... 6-8
Cleaning the air filter element ...... 6-10
Cleaning the spark arrester ......... 6-12
Adjusting the carburetor ............... 6-13
Adjusting the engine idling
speed ........................................ 6-13
Checking the throttle cable free
play ........................................... 6-14
Valve clearance ........................... 6-14
Tires ............................................. 6-15
Spoke wheels .............................. 6-16
Adjusting the clutch free play ....... 6-16Adjusting the brake lever free
play ........................................... 6-17
Adjusting the brake pedal free
play ........................................... 6-18
Checking the shift pedal ............... 6-19
Checking the front and rear brake
shoes ........................................ 6-19
Drive chain slack .......................... 6-20
Cleaning and lubricating the drive
chain ......................................... 6-21
Checking and lubricating the
cables ....................................... 6-22
Checking and lubricating the
throttle grip and cable ............... 6-22
Checking and lubricating the
brake lever ................................ 6-23
Checking and lubricating the
brake pedal ............................... 6-23
Checking and lubricating the
sidestand .................................. 6-23
Lubricating the swingarm pivots ... 6-24
Checking the front fork ................. 6-24
Checking the steering .................. 6-25
Checking the wheel bearings ....... 6-25
Battery .......................................... 6-25
Replacing the fuse ....................... 6-27
Supporting the motorcycle ........... 6-27
Front wheel .................................. 6-28
Rear wheel ................................... 6-29
Troubleshooting ........................... 6-31
Troubleshooting chart .................. 6-32
U5B681E0.book Page 1 Tuesday, June 17, 2008 5:48 PM

SAFETY INFORMATION
1-2
1


Many accidents have been caused
by error of the motorcycle opera-
tor. A typical error made by the op-
erator is veering wide on a turn
due to excessive speed or under-
cornering (insufficient lean angle
for the speed). Never travel faster
than warranted by conditions.


Ride cautiously in unfamiliar ar-
eas. You may encounter hidden
obstacles that could cause an ac-
cident.


The posture of the operator is im-
portant for proper control. The op-
erator should keep both hands on
the handlebar and both feet on the
operator footrests during operation
to maintain control of the motor-
cycle.


Never ride under the influence of
alcohol or other drugs.


Be sure the transmission is in neu-
tral before starting the engine.Protective apparel
The majority of fatalities from motor-
cycle accidents are the result of head
injuries. The use of a safety helmet is
the single most critical factor in the pre-
vention or reduction of head injuries.


Always wear an approved helmet.


Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.


The use of a jacket, heavy boots,
trousers, gloves, etc., is effective in
preventing or reducing abrasions
or lacerations.


Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.


Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause burns.Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing car-
bon monoxide can cause headaches,
dizziness, drowsiness, nausea, confu-
sion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be
present even if you do not see or smell
any engine exhaust. Deadly levels of
carbon monoxide can collect rapidly
and you can quickly be overcome and
unable to save yourself. Also, deadly
levels of carbon monoxide can linger
for hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poison-
ing, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.


Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.


Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

FOR YOUR SAFETY – PRE-OPERATION CHECKS
4-2
4
EAU15605
Pre-operation check list
ITEM CHECKS PAGE
FuelCheck fuel level in fuel tank.
Refuel if necessary.
Check fuel line for leakage.3-3
Engine oilCheck oil level in engine.
If necessary, add recommended oil to specified level.
Check vehicle for oil leakage.6-8
Front brakeCheck operation.
Lubricate cable if necessary.
Check lever free play.
Adjust if necessary.6-17, 6-19
Rear brakeCheck operation.
Check pedal free play.
Adjust if necessary.6-18, 6-19
Throttle gripMake sure that operation is smooth.
Check cable free play.
If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.6-14, 6-22
Control cablesMake sure that operation is smooth.
Lubricate if necessary.6-22
Drive chainCheck chain slack.
Adjust if necessary.
Check chain condition.
Lubricate if necessary.6-20, 6-21
Wheels and tiresCheck for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.6-15, 6-16
Shift pedalMake sure that operation is smooth.
Correct if necessary.6-19
U5B681E0.book Page 2 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-4
6
EAU35348
General maintenance and lubrication chart No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL ODOMETER READINGS
1000 km
(600 mi) or
1 month or
30 hours3000 km
(1800 mi) or
6 months or
90 hours5000 km
(3000 mi) or
12 months or
150 hours
1*ClutchCheck operation.
Adjust if necessary.√√√
2*Front brakeCheck operation.
Adjust brake lever free play and replace brake shoes if
necessary.√√√
3*Rear brakeCheck operation.
Adjust brake pedal free play and replace brake shoes if
necessary.√√√
4*WheelsCheck runout, spoke tightness and for damage.
Tighten spokes if necessary.√√√
5*TiresCheck tread depth and for damage.
Replace if necessary.
Check air pressure.
Correct if necessary.√√
6*Wheel bearingsCheck bearings for smooth operation.
Replace if necessary.√√
7*Swingarm pivot bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
8Drive chainCheck chain slack/alignment and condition.
Adjust and lubricate chain with Yamaha chain and cable
lube thoroughly.Every ride
9*Steering bearingsCheck bearing assemblies for looseness.
Moderately repack with lithium-soap-based grease.√√
U5B681E0.book Page 4 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-15
6
EAU39821
Tires To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified tires.
Tire air pressure
The tire air pressure should be checked
and, if necessary, adjusted before each
ride.
WARNING
EWA14381
Operation of this vehicle with im-
proper tire pressure may cause se-
vere injury or death from loss of
control.

The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).


The tire air pressure must be ad-
justed in accordance with the
weight of the rider, the riding
speed, and the riding condi-tions.Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail or
glass fragments in it, or if the sidewall is
cracked, have a Yamaha dealer re-
place the tire immediately.Tire information
This motorcycle is equipped with spoke
wheels and tube tires.
WARNING
EWA10461
The front and rear tires should be of
the same make and design, other-
wise the handling characteristics of
the vehicle may be different, whichcould lead to an accident.
After extensive tests, only the tires list-
ed below have been approved for this
model by Yamaha Motor Co., Ltd.
WARNING
EWA14390


Have a Yamaha dealer replace
excessively worn tires. Operat-
ing the motorcycle with exces-
Standard tire air pressure:
Fr o nt :
100 kPa (1.00 kgf/cm², 15 psi)
Rear:
100 kPa (1.00 kgf/cm², 15 psi)1. Tire sidewall
2. Tire tread depthMinimum tire tread depth (front and
rear):
4.0 mm (0.16 in)
12
Front tire:
Size:
2.50-14 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
Rear tire:
Size:
3.00-12 4PR
Manufacturer/model:
CHEN SHIN/C-803-2
U5B681E0.book Page 15 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-16
6 sively worn tires decreases
riding stability and can lead to
loss of control.


The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.


It is not recommended to patch
a punctured tube. If unavoid-
able, however, patch the tube
very carefully and replace it as
soon as possible with a high-quality product.
EAU21940
Spoke wheels To maximize the performance, durabil-
ity, and safe operation of your motor-
cycle, note the following points
regarding the specified wheels.

The wheel rims should be checked
for cracks, bends or warpage, and
the spokes for looseness or dam-
age before each ride. If any dam-
age is found, have a Yamaha
dealer replace the wheel. Do not
attempt even the smallest repair to
the wheel. A deformed or cracked
wheel must be replaced.


The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced. An
unbalanced wheel can result in
poor performance, adverse han-
dling characteristics, and a short-
ened tire life.


Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for it
to develop its optimal characteris-
tics.
EAU44663
Adjusting the clutch free play The clutch free play must be checked
and, if necessary, adjusted as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
1. Loosen the locknut.
2. Slowly turn the clutch adjusting
screw in direction (a) until resis-
tance is felt, and then turn it 1/8
turn in direction (b).
3. Tighten the locknut to the specified
torque.1. Locknut
2. Clutch adjusting screw
Tightening torque:
Locknut:
8.0 Nm (0.8 m·kgf, 5.8 ft·lbf)
12
(a)
(b)
U5B681E0.book Page 16 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-18
6 8. Tighten the locknut at the brake
shoe plate and at the brake lever.
9. Slide the rubber cover to its origi-
nal position.
EAU44670
Adjusting the brake pedal free
play The brake pedal free play should mea-
sure 10.0–20.0 mm (0.39–0.79 in) at
the brake pedal end as shown. Period-
ically check the brake pedal free play
and, if necessary, adjust it as follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod in
direction (a). To decrease the brake
pedal free play, turn the adjusting nut in
direction (b).
WARNING
EWA14820


After adjusting the drive chain
slack or removing and installing
the rear wheel, always check the
brake pedal free play.


If proper adjustment cannot be
obtained as described, have a
Yamaha dealer make this ad-justment.
1. Locknut
2. Brake lever free play adjusting bolt
21(b)
(a)
1. Brake pedal free play adjusting nut
2. Brake pedal free play
U5B681E0.book Page 18 Tuesday, June 17, 2008 5:48 PM

PERIODIC MAINTENANCE AND ADJUSTMENT
6-20
6
EAU22760
Drive chain slack The drive chain slack should be
checked before each ride and adjusted
if necessary.
EAU22773
To check the drive chain slack
1. Place the motorcycle on the side-
stand.TIPWhen checking and adjusting the drive
chain slack, there should be no weighton the motorcycle.
2. Shift the transmission into the neu-
tral position.
3. Move the rear wheel by pushing
the motorcycle to locate the tight-
est portion of the drive chain, and
then measure the drive chain slack
as shown.4. If the drive chain slack is incorrect,
adjust it as follows.
EAU40111
To adjust the drive chain slack
1. Loosen the brake pedal free play
adjusting nut, axle nut, and locknut
at each end of the swingarm.2. To tighten the drive chain, turn the
drive chain slack adjusting nut at
each end of the swingarm in direc-
tion (a). To loosen the drive chain,
turn the adjusting nut at each end
of the swingarm in direction (b),
and then push the rear wheel for-
ward. NOTICE: Improper drive
chain slack will overload the en-
gine as well as other vital parts
of the motorcycle and can lead
to chain slippage or breakage.
To prevent this from occurring,
keep the drive chain slack with-
in the specified limits.
[ECA10571]
Drive chain slack:
40.0–56.0 mm (1.57–2.20 in)
1. Drive chain slack
1
1. Brake pedal free play adjusting nut
2. Locknut
3. Drive chain slack adjusting nut
U5B681E0.book Page 20 Tuesday, June 17, 2008 5:48 PM